KH400 flywheel removal
My 1976 Kawasaki KH400 is lacking in the charging department. I’m planning to send the stator coils to a shop for rewinding, hopefully that will get the battery charging back where it should be.
The stator coils and CDI are behind the flywheel on the left side of the motor. To get the flywheel off, first remove the small bolt holding it on then use a flywheel puller. The flywheel puller can be a 16mm x 1.5 bolt or the rear axle off a KH400.
I tried the bolt and the flywheel wouldn’t budge. Not wanting to remove the exhaust pipes to get the rear axle, I found a KZ1000 front axle with the correct thread size/pitch. The flywheel still wouldn’t budge.
Some guys put a small grade 8 bolt in the hole, then put the flywheel puller on. The small bolt should push on the crank and pop the flywheel off. My first try, the bolt bent and got stuck. I fished it out, went to the hardware store and found a grade 8 then tried again. Still it wouldn’t come out and I was a little worried about mashing up the threads in the hole. Then I found the answer!
Pack the hole with grease, then thread the puller on and tighten. Grease, like brake fluid is not compressible. Tightening up on the puller, some grease will ooze out through the keyway and around the threads. Then eventually “pop” the flywheel comes off.
Note - the crank must be still while you do this, if the motor is in neutral the crank will just turn while you’re trying to tighten. So put the motor in gear then jam something in between the chain and sprocket. I used an old washcloth wrapped around a 1 inch pipe.
Make sure not to drop the flywheel on the ground, it’s delicate.